So I've searched and read a lot on fitting the mcmaster door seals. Several people reference using a piece of seal to form the correct edge profile, but I can't find any exact detail. So my question(s) are:

1. Do you slide the door seal on and then inject it with epoxy/cabosil mix and then slide it out of the way to form the proper door frame thickness?

2. Do you put a release agent/tape on the inside of the mcmaster seal channel, inject it with epoxy/cabosil mix, let it set-up and then remove it?

1. Sand down edge as required for seal to fit correctly all around the opening
2. Cut 2-3x 12-24" segments of seal
3. Mask frame where you don't want epoxy
4. Fill seal segments with flox+epoxy and then smoosh into place around door frame --- ensure the segments are fully seated (no release required)
5. Pull masking tape off
6. Wait for epoxy to cure and then peel off seal segments
7. Repeat until done

Make SURE the seal is fully seated when you install it, especially in the corners. I ended up starting in the corner, setting the seal, working out from the corner. If you start on a straight section, when you get to the corner and seat the seal it can stretch. When you walk away, the seal will try and contract, pulling it from the corner. (Don't ask how I know this). If you start in the corner, there will be no stretching into the corner...FWIY...

You will probably destroy the seal pieces used for molds when you remove them...

My original order of 25 feet of seal left me with about 2.5 feet leftover, which I used as a mold. Eventually the removal process ripped the innards out of the C-channel. For the second door, I used the piece I cut for final installation as the mold. Removal once did not seem to harm it at all. I wouldn't try it a 4th or 5th time, though, and expect to re-use it for a final installation.

The VAFForums come to you courtesy Delta Romeo, LLC. By viewing and participating in them you agree to build your plane using standardized methods and practices and to fly it safely and in accordance with the laws governing the country you are located in.